Methods and apparatus for rotary machinery inspection

Abstract

Methods, apparatus and systems for machinery testing and inspection using a manipulator are provided. The apparatus includes a tubular shaft, an operator end coupled to the tubular shaft and including a first spool rotatably coupled to the operator end, an effector including an attachment end that includes a second spool rotatably coupled to the attachment end, and a control cable channeled through the shaft from the first spool to the second spool. The control cable is wound at least partially around the first spool and is wound at least partially around the second spool such that rotation of the first spool rotates the second spool using the control cable.

1. A hand-held manipulator comprising:
 a tubular shaft; 
 an operator end coupled to said tubular shaft and comprising a first spool rotatably coupled to said operator end; 
 an effector comprising an attachment end that includes a second spool rotatably coupled to said attachment end; 
 a cable comprising a first end and a second end, said first end slidably coupled within a first aperture defined in said tubular shaft and coupled to said effector, said second end accessible at said operator end; 
 at least one inspection device operatively coupled to said second spool such that said at least one inspection device moves with said second spool and is rotatable with said second spool in a first direction away from a center axis of said tubular shaft, and is rotatable away from the center axis in a second direction that is opposite the first direction; and 
 a control cable channeled through said shaft from said first spool to said second spool, said control cable wound at least partially around said first spool, said control cable wound at least partially around said second spool such that rotation of said first spool rotates said second spool using said control cable. 
 
     
     
       2. A manipulator in accordance with  claim 1  wherein said effector is coupled to said tubular shaft through a flexible tube. 
     
     
       3. A manipulator in accordance with  claim 2  wherein a curvature of said flexible tube defines an angle between said effector and said tubular shaft. 
     
     
       4. A manipulator in accordance with  claim 3  wherein shortening said cable changes the angle defined between said effector and said tubular shaft. 
     
     
       5. A manipulator in accordance with  claim 1  wherein said at least one inspection device comprises at least one of a borescope, a dye penetrant applicator, an ultrasound probe, a light, a video camera, and an eddy current probe. 
     
     
       6. A manipulator in accordance with  claim 1  wherein said effector is configured to pass between a row of circumferentially-spaced vanes to access a row of circumferentially-spaced blades of a rotatable machine. 
     
     
       7. A test and inspection system comprising:
 a hand-held manipulator comprising:
 a tubular shaft coupled to an operator end at a first end and coupled to an effector at a second end opposite said first end, said operator end rotatably coupled to a first spool, said effector rotatably coupled to a second spool; 
 a control cable extending slidably through said tubular shaft from said first spool to said second spool, said control cable wound at least partially around said first spool, said control cable wound at least partially around said second spool such that rotation of said first spool rotates said second spool using said control cable, 
 a cable comprising a first end and a second end, said first end slidably coupled within a first aperture defined in said tubular shaft and coupled to said effector, said second end accessible at said operator end; and 
 an attachment end configured to operatively couple at least one inspection device to said second spool, such that said at least one inspection device moves with said second spool, and is rotatable with said second spool in a first direction away from a center axis of said tubular shaft, and is rotatable away from the center axis in a second direction that is opposite the first direction. 
 
 
     
     
       8. A test and inspection system in accordance with  claim 7  wherein said at least one inspection device comprises at least one of a borescope, a dye penetrant applicator, an ultrasound probe, a light, a video camera, and an eddy current probe. 
     
     
       9. A test and inspection system in accordance with  claim 7  wherein said effector is coupled to said tubular shaft through a flexible tube. 
     
     
       10. A test and inspection system in accordance with  claim 9  wherein a curvature of said flexible tube defines an angle between said effector and said tubular shaft. 
     
     
       11. A test and inspection system in accordance with  claim 10  wherein shortening said cable changes the angle defined between said effector and said tubular shaft. 
     
     
       12. A test and inspection system in accordance with  claim 7  wherein said effector is configured to pass between a row of circumferentially-spaced vanes to access a row of circumferentially-spaced blades of a rotatable machine. 
     
     
       13. A method of machinery testing and inspection using a hand-held manipulator that includes an operator end coupled to a first end of a manipulator body and an attachment end coupled to a second end of the manipulator body, said method comprising:
 inserting a first end of a cable into a first aperture defined in the body first end; 
 extending the first end of the cable to a second aperture defined in the attachment end; 
 coupling the first end of the cable to the attachment end such that the second end of the cable is accessible at the operator end; 
 attaching at least one inspection device to a rotatable spool portion coupled to the attachment end, such that the at least one inspection device moves with the rotatable spool portion; 
 positioning the at least one inspection device proximate a component to be inspected; and 
 repositioning the at least one inspection device with respect to the component by controlling the operator end of the manipulator. 
 
     
     
       14. A method in accordance with  claim 13  wherein attaching at least one inspection device comprises attaching at least one of a borescope, a dye penetrant applicator, an ultrasound probe, a light, a video camera, and an eddy current probe. 
     
     
       15. A method in accordance with  claim 13  wherein attaching at least one inspection device comprises releasably coupling the at least one inspection device to a rotatable spool portion of the attachment end, such that the at least one inspection device moves with the rotatable spool portion. 
     
     
       16. A method in accordance with  claim 15  wherein repositioning the at least one inspection device comprises rotating the rotatable spool portion of the attachment end using the operator end. 
     
     
       17. A method in accordance with  claim 16  wherein repositioning the at least one inspection device comprises manipulating a handle coupled to the operator end. 
     
     
       18. A method in accordance with  claim 17  wherein the operator end handle is coupled to an operator end spool, and wherein repositioning the at least one inspection device comprises linearly translating a control cable through the manipulator body from the operator end spool to the rotatable spool portion of the attachment end wherein the control cable is wound at least partially around the operator end spool and wound at least partially around the attachment end spool portion such that rotation of the operator end spool to the rotates the attachment end spool. 
     
     
       19. A method in accordance with  claim 13  wherein the manipulator body includes a first tubular portion coupled to a first end of a flexible portion and an effector coupled to a second end of the flexible portion, and wherein the first tubular portion and the effector are coupled through the flexible portion using the cable, said method further comprising withdrawing the cable from the first tubular portion to change the position of the effector with respect to the component. 
     
     
       20. A method in accordance with  claim 19  wherein a curvature of the flexible portion defines an angle between the first tubular portion and the effector and wherein withdrawing the cable from the first tubular portion comprises changing the angle defined between the first tubular portion and the effector.